engine cooling CHRYSLER VOYAGER 2001 Workshop Manual

NOTE: To remove the water pump pulley, it MUST
first be positioned between water pump housing
and drive hub. The pulley can then be removed with
the water pump assembly.
(5) Rotate pulley until openings in pulley align
with water pump drive hub spokes (Fig. 28). Move
pulley inward between pump housing and hub (Fig.
28).
(6) Position pulley to allow access to water pump
mounting bolts. Remove water pump mounting bolts
(Fig. 29).
(7) Remove water pump with the pulley loosely
positioned between hub and the pump body.
(8) Remove and discard the seal.
(9) Clean seal groove and sealing surfaces on
pump and timing chain case cover. Take care not to
scratch or gouge sealing surfaces.
CLEANING
Clean gasket mating surfaces as necessary.
INSPECTION
Replace the water pump if it has any of the follow-
ing defects.
(1) Damage or cracks on the pump body.
(2) Coolant leaks; this will be evident by a wet
stream of coolant running down the pump body and
components below. A thin stain below the weep hole
reservoir slot (Fig. 30) is considered normal opera-
tion.
(3) Impeller rubs inside of chain case cover.
(4) Excessively loose or rough turning bearing.
NOTE: A weepage stain that is black, brown, or grey
is considered normal, if it is dry. If the weep
appears wet; pressure test the cooling system at15±18 psi and observe the weep area. If weep area
remains unchanged, do not replace the water pump
for this condition. Replace the water pump, if a
steady flow of engine coolant is evident from the
weep hole/reservoir slot (Fig. 30) (shaft seal failure).
Be sure to perform a thorough analysis before
replacing water pump.
INSTALLATION
(1) Install new seal into water pump housing
groove (Fig. 31).
NOTE: The water pump pulley MUST be positioned
loosely between the pump housing and drive hub
BEFORE water pump installation.
Fig. 28 Water Pump Pulley Positioning
1 - HUB - WATER PUMP
2 - PULLEY - WATER PUMP
Fig. 29 Water Pump Bolts - 3.3/3.8L Engine (Shown
Without Pulley)
1 - WATER PUMP
2 - BOLTS
Fig. 30 Water Pump Inspection - 3.3/3.8L Engine
RSENGINE7-33
WATER PUMP - 3.3/3.8L (Continued)

(2) Position the water pump pulley loosely between
pump housing and drive hub (Fig. 28).
(3) Install water pump and pulley to the timing
chain case cover (Fig. 27). Tighten water pump bolts
to 12 N´m (105 in. lbs.).
(4) Position pulley on water pump hub. Install
bolts and tighten to 30 N´m (250 in. lbs.) (Fig. 27).
(5) Rotate pump by hand to check for freedom of
movement.
(6) Install the accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(7) Install drive belt shield.
(8) Fill the cooling system. (Refer to 7 - COOLING
- STANDARD PROCEDURE)
WATER PUMP INLET TUBE -
2.4L
DESCRIPTION
The 2.4L engine uses a metal tube to connect the
engine block to the lower radiator hose and heater
return (Fig. 32). The tube has an O-ring for block to
tube sealing and bolts attach the tube to the engine
block.
REMOVAL
(1) Drain the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(2) Remove radiator upper hose to access the hose
connections at the inlet tube.(3) Remove radiator lower (Fig. 7) and heater
hoses from the inlet tube (Fig. 33).
(4) Remove the two fasteners that hold the inlet
tube to the block.
(5) Rotate tube while removing the tube from the
engine block (Fig. 33).
INSTALLATION
(1) Inspect the O-ring for damage before installing
the tube into the cylinder block (Fig. 32).
(2) Lube O-ring with coolant and install inlet tube
into the cylinder block opening (Fig. 32).
(3) Install the two inlet tube fasteners and tighten
to 12 N´m (105 in. lbs.).
(4) Connect the radiator lower hose and heater
hose to inlet tube.
Fig. 31 Water Pump Seal
1 - WATER PUMP HOUSING
2 - SEAL
3 - IMPELLER
Fig. 32 Water Pump Inlet TubeÐ2.4L Engine
1 - O-RING
2 - WATER PUMP INLET TUBE
Fig. 33 Water Pump Inlet Tube Hose Connections
1 - WATER PUMP INLET TUBE
2 - HOSE - HEATER RETURN
3 - COOLANT INLET
7 - 34 ENGINERS
WATER PUMP - 3.3/3.8L (Continued)

(5) Install the radiator upper hose.
(6) Fill the cooling system. (Refer to 7 - COOLING
- STANDARD PROCEDURE)
WATER PUMP INLET TUBE -
3.3/3.8L
REMOVAL
(1) Drain the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(2) Raise vehicle on hoist and remove the belt
splash shield.
(3) Remove the radiator lower hose from inlet tube
(Fig. 34).
(4) Remove the oil cooler outlet/heater return hose
from inlet tube (only if equipped with engine oil
cooler) (Fig. 35).
(5) Remove the inlet tube bolts (Fig. 36).
(6) Remove the inlet tube (Fig. 36). Discard the
O-ring seal.
INSTALLATION
(1) Clean the inlet tube O-ring sealing surfaces on
the timing cover housing and tube.
(2) Apply MopartDielectric Grease or equivalent
to the O-ring before installation.
(3) Position new O-ring seal on inlet tube (Fig. 36).
(4) Install the inlet tube (Fig. 36). Tighten bolts to
28 N´m (250 in. lbs.).(5) Connect radiator lower hose (Fig. 34) and
heater return hose (if equipped with engine oil
cooler) (Fig. 35) to the inlet tube.
(6) Install the drive belt splash shield and lower
vehicle.
(7) Fill the cooling system. (Refer to 7 - COOLING
- STANDARD PROCEDURE)
Fig. 34 RAD HOSES TO ENGINE - 3.3/3.8L
1 - UPPER HOSE
2 - LOWER HOSE
Fig. 35 Engine Oil Cooler Hoses (Engine Oil Cooler
Equipped)
1 - OIL COOLER INLET TUBE
2 - INLET HOSE
3 - OIL COOLER OUTLET TUBE
4 - OUTLET HOSE
5 - WATER PUMP INLET TUBE
Fig. 36 WATER PUMP INLET TUBE
1 - TIMING CHAIN COVER
2 - INLET TUBE
3 - BOLT
4 - BOLT
5 - O-RING
RSENGINE7-35
WATER PUMP INLET TUBE - 2.4L (Continued)

TRANSMISSION
TABLE OF CONTENTS
page page
TRANSMISSION
DIAGNOSIS AND TESTING.................36
TRANS OIL COOLER FLOW TESTING.......36
STANDARD PROCEDURE..................37
FLUSHING COOLERS AND TUBES.........37
TRANS COOLER
DESCRIPTION...........................38REMOVAL..............................38
CLEANING..............................38
INSPECTION............................38
INSTALLATION...........................38
TRANS COOLER LINES
REMOVAL..............................38
INSTALLATION...........................39
TRANSMISSION
DIAGNOSIS AND TESTING - TRANSMISSION
OIL COOLER FLOW
To determine proper transmission oil flow through
the oil cooler perform the following procedure:
(1) Disconnect the hose from the ªcooler returnº
fitting on the transmission. (Refer to 7 - COOLING/
TRANSMISSION/TRANS COOLER LINES -
REMOVAL)
(2) Using Special Tool adaptors 6906-1-3 with a 9
mm (3/8 in.) transmission hose attached to oneadapter, connect Special Tool 8392 flow meter in-se-
ries with the oil cooler flow circuit (Fig. 1).
(3) Start engine and run at curb idle speed.
Observe the flow meter gauge. Refer to the following
chart for specifications.
COOLER FLOW SPECIFICATION (Min.)
2.6 LPM (0.7 GPM)
(4) If oil flow is below minimum specifications, fur-
ther diagnosis must be performed.
(a) Perform Oil Pump Volume Check. (Refer to
21 - TRANSMISSION/TRANSAXLE/AUTOMATIC
Fig. 1 TRANS COOLER FLOW TEST
1 - SPECIAL TOOL 8392 4 - TRANS HOSE-9mm(3/89I.D.)
2 - SPECIAL TOOL 6906-1-3 5 - FROM COOLER
3 - TO TRANS
7 - 36 TRANSMISSIONRS

TRANS COOLER
DESCRIPTION
The transmission oil cooler is an external oil-to-air
type cooler is mounted between the front of the radi-
ator and back side of the A/C condensor (Fig. 3). Use
only approved transmission oil cooler hoses that are
molded to fit the space available.
REMOVAL
(1) Remove the radiator. (Refer to 7 - COOLING/
ENGINE/RADIATOR - REMOVAL)
(2) Disconnect lines from oil cooler (Fig. 2).
(3) Remove oil cooler attaching screws (Fig. 3).
(4) Remove the oil cooler.
CLEANING
Check the external cooler for debris on the cooling
fin surfaces. Clean as necessary. For internal clean-
ing/flushing procedures, (Refer to 7 - COOLING/
TRANSMISSION - STANDARD PROCEDURE).
INSPECTION
Inspect all hoses, tubes, clamps and connections for
leaks, cracks, or damage. Replace as necessary. Use
only approved transmission oil cooler hoses that are
molded to fit the space available.
Inspect external coolers for leaks, loose mounts, or
damage. Replace as necessary.
INSTALLATION
(1) Install transaxle oil cooler and mounting
screws (Fig. 3).
NOTE: When replacing the transmission oil cooler,
the cooler hoses must be replaced.
(2) Connect the new cooler hoses and install
clamps (Fig. 2).
(3) Install the radiator. (Refer to 7 - COOLING/
ENGINE/RADIATOR - INSTALLATION)
(4) Start engine. Check and adjust the fluid level
as necessary.
TRANS COOLER LINES
REMOVAL
(1) Using appropriate hose clamp pliers, release
tension on clamps and move off fittings.
NOTE: When the transaxle cooler lines are removed
from the rolled-groove type fittings at the cooler
and transaxle, damage to the inner wall of hose will
occur. To prevent potential leakage, the cooler
hoses must be replaced.
(2) Remove the hoses (Fig. 4) or (Fig. 5).
Fig. 2 TRANSMISSION COOLER HOSES
1 - TRANSAXLE COOLER HOSES
2 - FITTING - COOLER OUTLET
3 - FITTING - COOLER INLET
Fig. 3 Transmission Oil Cooler
1 - TRANSAXLE OIL COOLER
2 - SCREWS
3 - A/C CONDENSOR (REAR SIDE)
7 - 38 TRANSMISSIONRS

COOLING 2.5L TURBO DIESEL
TABLE OF CONTENTS
page page
COOLING 2.5L TURBO DIESEL
DESCRIPTION............................1
DIAGNOSIS AND TESTING..................1
COOLING SYSTEM......................1
COOLING SYSTEM LEAK TEST.............6
COOLING SYSTEM FLOW CHECK..........7COOLING SYSTEM AERATION.............7
CLEANING...............................7
INSPECTION.............................7
SPECIFICATIONS.........................8
ACCESSORY DRIVE.......................9
ENGINE................................14
COOLING 2.5L TURBO DIESEL
DESCRIPTION - COOLING SYSTEM
The cooling system regulates engine operating tem-
perature. It allows the engine to reach normal oper-
ating temperature as quickly as possible, maintains
normal operating temperature and prevents over-
heating.
The cooling system also provides a means of heat-
ing the passenger compartment. The cooling system
is pressurized and uses a centrifugal water pump to
circulate coolant throughout the system. A separate
and remotely mounted, pressurized coolant tank
using a pressure/vent cap is used.
COOLING SYSTEM COMPONENTS
The cooling system consists of:
²Charge Air Cooler
²Electric Cooling Fans
²A aluminum-core radiator with plastic side
tanks
²A separate pressurized coolant tank
²A pressure/vent cap on the coolant tank
²Fan shroud
²Thermostat
²Coolant
²Low coolant warning lamp
²Coolant temperature gauge
²Water pump
²Hoses and hose clamps
DIAGNOSIS AND TESTING - COOLING SYSTEM
Establish what driving conditions caused the com-
plaint. Abnormal loads on the cooling system such as
the following may be the cause:
(1) PROLONGED IDLE, VERY HIGH AMBIENT
TEMPERATURE, SLIGHT TAIL WIND AT IDLE,
SLOW TRAFFIC, TRAFFIC JAMS, HIGH SPEED
OR STEEP GRADES.
Driving techniques that avoid overheating are:
²Idle with A/C off when temperature gauge is at
end of normal range.
²Increasing engine speed for more air flow is rec-
ommended.
(2) TRAILER TOWING:
Consult Trailer Towing section of owners manual.
Do not exceed limits.
(3) RECENT SERVICE OR ACCIDENT REPAIR:
Determine if any recent service has been per-
formed on vehicle that may effect cooling system.
This may be:
²Engine adjustments (incorrect timing)
²Slipping engine accessory drive belt
²Brakes (possibly dragging)
²Changed parts (incorrect water pump)
²Reconditioned radiator or cooling system refill-
ing (possibly under filled or air trapped in system).
NOTE: If investigation reveals none of the previous
items as a cause for an engine overheating com-
plaint, refer to following Cooling System Diagnosis
charts.
These charts are to be used as a quick-reference
only.
RGCOOLING 2.5L TURBO DIESEL7a-1

COOLING SYSTEM DIAGNOSIS-DIESEL ENGINE
CONDITION POSSIBLE CAUSES CORRECTION
TEMPERATURE GAUGE
READS LOW1. Diesel engines, due to their
inherent effiency are slower to warm
up than gasoline powered engines,
and will operate at lower
temperatures when the vehicle is
unloaded.1. The low gauge reading may
be normal. Refer to thermostats
in the manual text for
information. See Thermostat
Diagnosis-Diesel Engine.
2. Is the temperature gauge
connected to the temperature gauge
coolant sensor on the engine?2. Check, the engine
temperature sensor connector
in the engine compartment.
3. Is the temperature gauge
operating OK?3. Check gauge operation.
Repair as necessary.
4. Coolant level low in cold ambient
temperatures accompanied with poor
heater performance.4. Check coolant level in the
coolant tank. Inspect system for
leaks. Repair leaks as
necessary. Refer to the Coolant
section for WARNINGS and
precautions before removing
the pressure cap.
5. Improper operation of internal
heater doors or heater controls.5. Inspect heater and repair as
necessary. Refer to Heating
and Air Conditioning for
procedures.
TEMPERATURE GAUGE
READS HIGH. COOLANT
MAY OR MAY NOT BE
LOST OR LEAKING FROM
COOLING SYSTEM1. Trailer is being towed, a steep hill
is being climbed, vehicle is operated
in slow moving traffic, or engine is
being idled with very high ambient
(outside) temperature and the air
conditioning is on. Higher altitudes
could aggravate these conditions.1. This may be a temporary
condition and repair is not
necessary. Turn off the air
conditioning and attempt to
drive the vehicle without any of
the previous conditions.
Observe the temperature
gauge. The gauge should return
to the normal range. If the
gauge does not return to
normal range, determine the
cause for the overheating and
repair.
2. Temperature gauge reading
incorrectly.2. Check gauge. Refer to I/P
group.
3. Coolant low in coolant tank and
radiator.3. Check for coolant leaks and
repair as necessary.
4. Pressure cap not installed tightly.
If cap is loose, boiling point of
coolant will be lowered.4. Tighten cap.
5. Poor seals at pressure/vent cap. 5. (a) Check condition of cap
and cap seals. (b) Check
condition of coolant tank filler
neck. Make sure it does not
leak pressure.
7a - 2 COOLING 2.5L TURBO DIESELRG
COOLING 2.5L TURBO DIESEL (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
6. Freeze point of antifreeze not
correct. Mixture may be too rich.6. Check antifreeze. Adjust
antifreeze-to-water ratio as
required.
7. Coolant not flowing through
system.7. Check for coolant flow in
coolant tank with engine warm
and thermostat open. Coolant
should be observed flowing
through the tank. If flow is not
observed, determine reason for
lack of flow and repair as
necessary.
8. Radiator or A/C condensor fins
are dirty or clogged.8. Clean debris from radiator or
A/C condensor
9. Radiator core is corroded or
plugged.9. Have radiator re-cored or
replaced.
10. Aftermarket A/C installed without
proper A/C condensor.10. Install proper A/C
condensor.
11. Dragging Brakes. 11. Check and correct as
necessary.
12. Non-factory bug screen is being
used reducing airflow.12. Only a factory screen
should be used.
13. Thermostat partially or
completely shut. This is more
prevalent on high mileage vehicles.13. Check thermostat and
replace if necessary.
14. Cylinder head gasket leaking. 14. Check cylinder head gasket
for leaks.
15. Heater core leaking. 15. Check heater cor for leaks.
Repair as necessary.
TEMPERATURE GAUGE
READING IS
INCONSISTENT
(FLUCTUATES, CYCLES
OR IS ERRATIC)1. During cold weather operation,
with the heater blower in the high
position, the gauge reading may
drop slightly. Fluctuation is also
influenced by loads, outside
temperature and extended idle time
with diesel engines.1. A normal condition. No
correction is necessary.
2. Temperature gauge or engine
mounted gauge sensor defective or
shorted. Also, corroded or loose
wiring in this circuit.2. Check operation of gauge
and repair as necessary.
3. Gauge reading rises when vehicle
is brought to a stop after heavy use
(engine still running).3. A normal condition. No
correction needed. Gauge
should return to normal range
after vehicle is driven.
4. Gauge reading high after starting
a warm-iup (hot) engine.4. A normal condition. No
correction needed. Gauge
should return to normal after a
few minutes of engine
operation.
RGCOOLING 2.5L TURBO DIESEL7a-3
COOLING 2.5L TURBO DIESEL (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
5. Coolant level low in the coolant
tank (air will build up in the cooling
system causing the thermostat to
open late).5. Check and correct coolant
leaks.
6. Cylinder head gasket leaking
allowing exhaust gases to enter the
cooling system causing the
thermostat to open late.6. (a) Check for cylinder head
gasket leaks with a
commercially available leak
tester. (b) Check for coolant in
engine oil. Inspect for white
steam emitting from exhaust
system. Repair as necessary.
7. Water pump impeller loose on
shaft.7. Check water pump and
replace as necessary.
8. Loose accessory drive belt (water
pump slipping).8. Check and correct as
necessary.
9. Air leak on the suction side of the
water pump allowing air to build up
in the cooling system causing the
thermostat to open late.9. Locate leak and repair as
necessary.
PRESSURE CAP IS
BLOWING OFF STEAM
AND/OR COOLANT.
TEMPERATURE GAUGE
READING MAY BE ABOVE
NORMAL BUT NOT HIGH.
COOLANT LEVEL MAY BE
HIGH IN COOLANT TANK1. Pressure relief valve in pressure/
vent cap is defective.1. Check condition of
pressure/vent cap and cap
seals.
2. Head gasket leak or cracked
cylinder head.2. Repair as necessary.
COOLANT LOSS TO THE
GROUND WITHOUT
PRESSURE CAP
BLOWOFF. GAUGE IS
READING HIGH OR HOT1. Coolant leaks in radiator, cooling
system hoses, water pump, or
engine.1. Pressure test cooling system
and repair as necessary.
HOSE OR HOSES
COLLAPSE WHEN
ENGINE IS COOLING1. Vacuum created in cooling system
on engine cool-down is not being
relieved through pressure/vent cap.1. Cap relief valve stuck.
Replace if necessary.
NOISY FAN 1. Cooling fan blades loose. 1. Replace cooling fan
assembly.
2. Cooling fan blades striking a
surrounding object.2. Locate point of fan blade
contact and repair as
necessary.
3. Air obstructions at radiator or A/C
condensor.3. Remove obstructions or
clean debris from radiator or
A/C condensor.
7a - 4 COOLING 2.5L TURBO DIESELRG
COOLING 2.5L TURBO DIESEL (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
INADEQUATE AIR
CONDITIONER
PERFORMANCE
(COOLING SYSTEM
SUSPECTED)1. Radiator and/or A/C condensor is
restricted, obstructed or dirty
(insects, leaves, etc.)1. Remove restriction or clean
debris from radiator or A/C
condensor.
2. Engine is overheating (heat may
be transferred from radiator to A/C
condensor. High underhood
temperatures due to engine
overheating may also transfer heat
to A/C condensor).2. Correct overheating
condition.
3. The cooling system is equipped
with air seals at the radiator and/or
A/C condensor. If these seals are
missing or damaged, not enough air
flow will be pulled through the
radiator and A/C condensor.3. Check for missing or
damaged air seals. Repair as
necessary.
INADEQUATE HEATER
PERFORMANCE. MAY BE
ACCOMPANIED BY LOW
GAUGE READING1. Diesel engines, due to their
inherent efficiency are slower to
warm up than gasoline powered
engines, and will operate at lower
temperatures when the vehicle is
unloaded.1. The lower gauge reading
may be normal.
2. Coolant level low. 2. Pressure test cooling system.
Repair leaks as necessary.
3. Obstruction in heater hose fitting
at engine.3. Remove heater hoses and
check for obstructions. Repair
as necessary.
4. Heater hose kinked. 4. Locate kinked area. Repair
as necessary.
5. Water pump is not pumping water
to heater core. When the engine is
fully warmed up, both heater hoses
should be hot to the touch. If only
one of the hoses is hot the water
pump may not be operating correctly.
The accessory drive belt may also
be slipping causing poor water pump
operation.5. Refer to water pumps in this
group. Repair as necessary. If a
slipping belt is detected, refer to
Engine Accessory Drive Belts in
this group. Repair as
necessary.
HEAT ODOR 1. Various heat shields are used at
certain drive line components. One
or more of these shields may be
missing.1. Locate missing shields.
Repair or replace as necessary.
2. Is temerature gauge reading
above the normal range?2. Refer to the previous
Temperature Gauge Reads
High in these Diagnostic
Charts. Repair as necessary.
3. Is the Cooling fan operating
correctly?3. Refer to Cooling System Fan
in this group for diagnosis.
Repair as necessary.
RGCOOLING 2.5L TURBO DIESEL7a-5
COOLING 2.5L TURBO DIESEL (Continued)